Composite faucet body and internal waterway

ABSTRACT

The present application generally relates to a faucet. The faucet includes a continuous internal waterway and a body. The continuous internal waterway includes a first chamber, a second chamber, a valve seat, and a waterway. The second chamber is configured to receive water from a water source. The valve seat is coupled to the first chamber and the second chamber. The valve seat is in fluid communication with the second chamber. The waterway is in fluid communication with the valve seat. The body encapsulates the continuous internal waterway. The faucet is operational to receive the water from the water source and to provide the water to the waterway. The body is isolated from the water by the continuous internal waterway during operation of the faucet.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of, and priority to, U.S.Provisional Patent Application No. 62/327,536, filed Apr. 26, 2016, theentirety of which is incorporated by reference herein.

BACKGROUND

The present application relates generally to faucet assemblies. Inparticular, this application relates to the construction of a faucetbody and an internal waterway.

Faucet assemblies may include a faucet body, handles, valve cartridges,and a plumbing network. Faucet bodies may be configured to be coupled tothe handles, valve cartridges, and plumbing network of the faucetassembly. Faucet bodies may be manufactured by forming the faucet bodyaround a core (i.e., in a cast or mold). Faucet bodies areconventionally constructed from a metallic material such as brass orzinc. The core may maintain an empty space within the faucet body formixing or ingress channels. When the core is removed from the faucetbody, in a post-processing step, the body may require machining,polishing, and/or buffing of the surface. After the core is removed,internal components may be installed inside the faucet body. Afterinstalling the internal components in the faucet body, the faucetassembly may then be installed in an application.

SUMMARY

One embodiment of the present disclosure relates to faucet. The faucetincludes a continuous internal waterway and a body. The continuousinternal waterway includes a first chamber, a second chamber, a valveseat, and a waterway. The second chamber is configured to receive waterfrom a water source. The valve seat is coupled to the first chamber andthe second chamber. The valve seat is in fluid communication with thesecond chamber. The waterway is in fluid communication with the valveseat. The body encapsulates the continuous internal waterway. The faucetis operational to receive the water from the water source and to providethe water to the waterway. The body is isolated from the water by thecontinuous internal waterway during operation of the faucet.

Another embodiment of the present disclosure relates to a method forconstructing a water faucet. The method includes coupling a valve seatto a bottom chamber and to a waterway. The valve seat, bottom chamber,and waterway form a continuous internal waterway. The method alsoincludes placing the continuous internal waterway in a mold. The methodalso includes forming a body around the continuous internal waterway bysurrounding the continuous internal waterway with encapsulating materialin the mold. The method also includes removing the body from the mold.The continuous internal waterway is configured to receive water throughthe bottom chamber. The continuous internal waterway is also configuredto provide water through the valve seat to the waterway. The continuousinternal waterway is also configured to provide water from the waterway.The continuous internal waterway is continuous within the body

Yet another embodiment of the present disclosure relates to a processfor manufacturing a faucet. The process includes coupling a valve seatto an adjustable valve system, a waterway, and a bottom chamber suchthat the valve seat, the adjustable valve system, the waterway, and thebottom chamber are in fluid communication, thereby forming a continuousinternal waterway. The process also includes covering the adjustablevalve system with a print area cover. The print area cover is removablycoupled to the valve seat. The print area cover is configured tocooperate with the valve seat to cover the adjustable valve system. Theprocess also includes encapsulating the continuous internal waterway ina mold with a non-metallic encapsulating material, thereby forming abody around the continuous internal waterway. The process also includesremoving the body from the mold. The print area cover prevents thenon-metallic encapsulating material from contacting the adjustable valvesystem. The continuous internal waterway is configured to receive waterthrough the bottom chamber. The continuous internal waterway is alsoconfigured to provide water through the valve seat to the waterway. Thecontinuous internal waterway is also configured to provide water fromthe waterway.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory only,and are not restrictive of the invention as claimed.

The invention is capable of other embodiments and of being carried outin various ways. Alternative exemplary embodiments relate to otherfeatures and combinations of features.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-section view of a faucet preassembly including acontinuous internal waterway, according to an exemplary embodiment ofthe present disclosure;

FIG. 2 is a cross-section view of a faucet, according to an exemplaryembodiment of the present disclosure;

FIG. 3 is a perspective view of a continuous internal waterway for afaucet, according to an exemplary embodiment of the present disclosure;

FIG. 4 is a cross-section view of the continuous internal waterway shownin FIG. 3;

FIG. 5 is another cross-section view of the continuous internal waterwayshown in FIG. 3;

FIG. 6 is yet another cross-section view of the continuous internalwaterway shown in FIG. 3;

FIG. 7 is a flow chart illustrating a method for constructing a faucet,such as the faucet shown in FIG. 2, according to an exemplary embodimentof the present disclosure; and

FIG. 8 is a flow chart illustrating a process for manufacturing afaucet, such as the faucet shown in FIG. 2, according to an exemplaryembodiment of the present disclosure.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Referring to the Figures generally, various embodiments disclosed hereinrelate to a faucet constructed from plastic or composite material andhaving a fully assembled and complete internal waterway. The completeinternal waterway may be assembled separate from the faucet. Thecomplete internal waterway may be fully functional prior to beinginstalled in the faucet. Print area covers may be attached on thecomplete internal waterway at various openings. The continuous internalwaterway may be positioned in a mold. The print area covers may mountthe continuous internal waterway to the mold. The mold may be configuredin any desirable shape, thereby allowing the shape of the faucet to betailored for a target application. The shape of the faucet may not beconstrained by the continuous internal waterway. In some embodiments,the mold is configured to impart desired surface characteristics (e.g.,roughness, design, texture, etc.) on the faucet.

The continuous internal waterway may be partially or completely encasedin an encapsulating material in the mold. The continuous internalwaterway may be defined by a maximum temperature. The maximumtemperature may be a temperature at which components of the continuousinternal waterway are undesirably affected. The encapsulating materialmay be a plastic or composite material. The encapsulating material maybe defined by a processing temperature. The processing temperature maybe a temperature at which the encapsulating material may be poured intothe mold and around the continuous internal waterway. The processingtemperature may be lower than the maximum temperature. In someembodiments, the processing temperature is lower than the maximumtemperature by a factor of safety. Once removed from the mold, printarea covers may be removed. No assembly of internal faucet componentsmay be required once the faucet is removed from the mold.

Referring to FIG. 1, a faucet preassembly, shown as faucet preassembly100, includes internal plumbing, shown as continuous internal waterway110, that is encased (e.g., encapsulated, contained, etc.) in a body,shown as body 112, that is formed from encapsulating material (e.g.,permanent material, molding material, etc.). According to an exemplaryembodiment, continuous internal waterway 110 includes a first chamber(e.g., section, portion, etc.), shown as upper chamber 114, and a secondchamber (e.g., section, portion, etc.), shown as bottom chamber 116.Upper chamber 114 may be continuous with bottom chamber 116. In variousembodiments, continuous internal waterway 110 includes a valve system,shown as adjustable valve system 120, a valve housing (e.g., puck,etc.), shown as valve seat 130, a waterway (e.g., conduit, connector,etc.), shown as waterway 140, and an aerator, shown as aerator 150. Asshown in FIG. 1, adjustable valve system 120 is positioned within upperchamber 114. Valve seat 130 functions to fluidly couple upper chamber114 to bottom chamber 116. In some embodiments, valve seat 130 fluidlyand structurally couplers upper chamber 114 to bottom chamber 116. In anexemplary embodiment, upper chamber 114 is integrated within valve seat130. In another embodiment, bottom chamber 116 is integrated withinvalve seat 130. In yet another embodiment, both upper chamber 114 andbottom chamber 116 are integrated within valve seat 130. Upper chamber114 defines an opening (e.g., aperture, hole, etc.), shown as topopening 152, and bottom chamber 116 defines an opening (e.g., aperture,hole, etc.), shown as bottom opening 160. Top opening 152 and bottomopening 160 facilitate access into continuous internal waterway 110 fromoutside of continuous internal waterway 110.

According to an exemplary embodiment, continuous internal waterway 110includes a first cover (e.g., cap, lid, support, etc.), shown as topopening print area cover 170, that is positioned over top opening 152, asecond cover (e.g., cap, lid, support, etc.), shown as bottom openingprint area cover 180 that is positioned over bottom opening 160, and athird cover, shown as aerator print area cover 190, that is positionedover aerator 150. In some embodiments, continuous internal waterway 110does not include top opening print area cover 170, bottom opening printarea cover 180, or aerator print area cover 190. Adjustable valve system120 is shown in FIG. 1 to include a stem, shown as valve stem 192. Valveseat 130 may include a number of plumbing connections, shown as plumbingconnections 194. As shown in FIG. 1, continuous internal waterway 110 iscompletely encased within body 112. In other embodiments, continuousinternal waterway 110 is only partially encased within body 112.

In some applications, each of top opening print area cover 170, bottomopening print area cover 180, and aerator print area cover 190 mayinclude an opening. As shown in FIG. 1, aerator print area cover 190includes an opening, shown as opening 198. In alternative examples,aerator print area cover 190 does not include opening 198. Aerator printarea cover 190 may facilitate mounting of continuous internal waterway110 within a mold. For example, aerator print area cover 190 may attachto a mounting point within the mold. Further, aerator print area cover190 may substantially prevent encapsulating material from enteringcontinuous internal waterway 110.

Referring to FIG. 2, a faucet, shown as faucet 200, includes all thecomponents of faucet preassembly 100 except for top opening print areacover 170, bottom opening print area cover 180, and aerator print areacover 190. According to an exemplary embodiment, construction of faucet200 occurs in an assembly stage, a pre-forming stage, a forming stage,and a post-forming stage. In the assembly stage, continuous internalwaterway 110 is assembled. For example, continuous internal waterway 110may be assembled by a worker (e.g., laborer, assembly person, etc.), arobotic device, an automated assembly line, or a combination thereof.Once assembled, continuous internal waterway 110 may provide allnecessary connections for operations of faucet 200 (e.g., mixing ofwater streams, dispersal of mixed water streams, etc.). In oneembodiment, continuous internal waterway 110 can operate as a fullyfunctional faucet once connected to an operational plumbing network(e.g., a water supply) and a valve handle assembly. In variousembodiments, continuous internal waterway 110 is assembled and thencoupled to top opening print area cover 170, bottom opening print areacover 180, and aerator print area cover 190.

In the pre-forming stage, a forming process is selected and prepared,continuous internal waterway 110 is prepared for the forming process,and the encapsulating material of body 112 is selected. Body 112 may bedefined by a processing temperature at which the encapsulating materialmay be formed around a mold. Body 112 may be chosen such that a desiredconfiguration of continuous internal waterway 110 is suitable for theprocessing temperature of body 112. Continuous internal waterway 110 maybe defined by a maximum temperature at which components of continuousinternal waterway 110 may become undesirably affected. The processingtemperature of the encapsulating material of body 112 may be lower thanthe maximum temperature of continuous internal waterway 110. Accordingto various embodiments, the encapsulating material of body 112 is chosensuch that the processing temperature of the encapsulating material ofbody 112 is lower than the maximum temperature of continuous internalwaterway 110. The difference between the maximum temperature and theprocessing temperature may be expressed by a factor of safety calculatedby, for example, computing the ratio of the maximum temperature to theprocessing temperature. In some embodiments, the continuous internalwaterway 110 has a factor of safety of 1.3, 1.4, 1.6, and other similarvalues. In some embodiments, the maximum temperature of continuousinternal waterway 110 is one-hundred and fifty degrees Celsius.

Conventional faucets may be assembled by first casting a faucet bodyfrom a molten metal. A processing temperature of a conventional faucetbody may be greater than four-hundred degrees Celsius. Becauseconventional faucets are cast from molten metal, only certain featuresmay be incorporated into the faucet through the casting process such asingress or mixing channels. In the assembly of a conventional faucet,internal faucet components are assembled within the faucet after themetal body has cooled. Faucet 200 may be constructed without the need toassemble components within faucet 200 after faucet 200 is removed from amold.

Conventional faucets may be cast from corrosion resistant metals, suchas brass, which may require machining, polishing, and buffing. Further,flaws in conventional faucets may not be discovered until later steps ina manufacturing process. In other examples, conventional faucets may becast from corrosion susceptible metals, such as zinc, and therefore maynot be suitable for direct contact with water. Accordingly, additionalcomponents (e.g., ingress and mixing channels, etc.) may need to beassembled in the conventional faucet after casting requiring additionalassembly time. Accordingly, conventional faucets may be undesirablyexpensive. Faucet 200 may be formed with body 112 being constructed fromlow-cost encapsulating material such as plastics or composites. The body112 may be constructed from corrosion resistant encapsulating materialand may not require machining, polishing, or buffing. For example, body112 may be constructed from encapsulating material that does not containany metal and may not corrode.

Top opening print area cover 170, bottom opening print area cover 180,and aerator print area cover 190 may be coupled to a mold in variouslocations such that a desired configuration of faucet 200 may beachieved. Top opening print area cover 170, bottom opening print areacover 180, and aerator print area cover 190 may have various wallthicknesses and be constructed of various materials depending on thedesired forming process of faucet 200. For example, the processingtemperature of encapsulating material 196 and/or the maximum temperatureof continuous internal waterway 110 may influence the wall thickness ofthe top opening print area cover 170, bottom opening print area cover180, and aerator print area cover 190. In other embodiments, acombination of the wall thickness and the material of the top openingprint area cover 170, bottom opening print area cover 180, and aeratorprint area cover 190 is altered depending on the processing temperatureof encapsulating material 196 and/or the maximum temperature ofcontinuous internal waterway 110.

Top opening print area cover 170, bottom opening print area cover 180,and aerator print area cover 190 may be formed from a separate processas those mentioned for faucet 200. Additionally, top opening print areacover 170, bottom opening print area cover 180, and aerator print areacover 190 may be formed from different processes or of differentmaterials than the encapsulating material of body 112. Top opening printarea cover 170, bottom opening print area cover 180, and aerator printarea cover 190 may couple to continuous internal waterway 110 throughthe use of a variety of different mechanisms such as interlocking ofthreaded interfaces, adhesives, ultrasonic welding, friction fits, orother suitable mechanisms such that faucet 200 may be tailored for atarget application.

In one embodiment, top opening print area cover 170, bottom openingprint area cover 180, and aerator print area cover 190 each individuallycontain a threaded pattern that is configured to threadably mate with amatching threaded pattern on continuous internal waterway 110. Inanother embodiment, top opening print area cover 170, bottom openingprint area cover 180, and aerator print area cover 190 individuallycontain tabs (e.g., protrusions, protuberances, tangs, teeth, etc.)configured to fit within slots (e.g., recesses, receivers, channels,etc.) within continuous internal waterway 110. In yet anotherembodiment, top opening print area cover 170, bottom opening print areacover 180, and aerator print area cover 190 are individually affixedwithin continuous internal waterway 110 through the use of a permanentor temporary adhesive (e.g., glue, epoxy, cement, rubber cement, vinylcement, etc.). In yet another embodiment, top opening print area cover170, bottom opening print area cover 180, and aerator print area cover190 are individually affixed within continuous internal waterway 110through the use of ultrasonic welds from an ultrasonic welding process.In other embodiments, top opening print area cover 170, bottom openingprint area cover 180, and aerator print area cover 190 are individuallyaffixed within continuous internal waterway 110 through the use of hotgas welding, heat sealing, speed tip welding, extrusion welding, contactwelding, hot plate welding, high frequency welding, induction welding,injection welding, friction welding, spin welding, laser welding, orsolvent welding.

The top opening print area cover 170, bottom opening print area cover180, and aerator print area cover 190 may be configured to cover (e.g.,protect, shield, etc.) certain regions of continuous internal waterway110 from body 112. Certain regions of continuous internal waterway 110,such as aerator 150, valve stem 192, adjustable valve system 120, andbottom opening 160, may not be intended for contact with body 112.

In the forming stage, continuous internal waterway 110 is aligned in amold and body 112 is formed around continuous internal waterway 110resulting in faucet preassembly 100. In some embodiments, body 112solidifies (e.g., cures, sets, etc.) after a certain period of time. Invarious examples, body 112 may solidify as a result of chemicalcrosslinking, cooling, evaporation of carrying solvents, or othersolidification processes. In one application, body 112 is constructedfrom an encapsulating material that is a composite material with apermanent cross-link network. The permanent cross-link network mayprevent problems normally associated with composite molding such asstress cracking, physical aging, and creep. In some applications,certain portions of the mold containing continuous internal waterway 110may be locally heated or cooled. In other applications, the entire moldcontaining continuous internal waterway 110 may be heated or cooled.

In various embodiments, faucet 200 is formed via a molding process whichutilizes a mold (e.g., core, blank, etc.). In one embodiment, faucet 200is formed via an injection molding process. In other embodiments, faucet200 is formed via a casting process which utilizes a mold (e.g., core,blank, etc.). According to various embodiments, faucet 200 is formed viasand casting, permanent mold casting, investment casting, lost foamcasting, die casting, centrifugal casting, glass casting, or slipcasting. According to other embodiments, faucet 200 is formed via blowmolding, powder metallurgy and sintering, compression molding, extrusionmolding, laminating, reaction injection molding, die casting, thin-wallinjection molding, matrix molding, rotational molding (e.g.,rotomolding, etc.), spin casting, transfer molding, thermoforming, orvacuum forming. According to various embodiments, faucet 200 is formedthrough the use of a silicon mold. In some embodiments, faucet 200 isformed through an injection molding process defined by an injectionpressure. In one example, the injection pressure may be betweenthirty-four kilopascals and one-hundred and four kilopascals.

According to various exemplary embodiments, continuous internal waterway110 serves as the core of a mold. In these embodiments, body 112 isformed around continuous internal waterway 110 within the mold.Depending on the configuration of the mold, various sections of faucet200 may have a different wall thickness (e.g., a thickness of body 112between an outside surface of faucet 200 and continuous internalwaterway 110). For example, the thickness of body 112 that surroundswaterway 140 may be greater than the thickness of body 112 thatsurrounds adjustable valve system 120. The mold may allow faucet 200 toobtain any desired shape or configuration. For example, the mold mayallow a spout of faucet 200 to have a target shape such as a prism,cylinder, rectangle, or other shape such that faucet 200 may be tailoredfor a target application. Faucet 200 may have a shape that is notconstrained by continuous internal waterway 110. In some embodiments,faucet 200 has an unconventional or application tailored shape. Further,different shapes of faucet 200 may be utilized with the same continuousinternal waterway 110. In contrast, a conventional faucet may have ashape that is constrained by internal components and the ability toinstall the internal components within the conventional faucet.Similarly, the mold may allow faucet 200 to have any desired surfacecharacteristics such as texture and design. For example, the mold may bepolished allowing faucet 200 to have a polished surface when removedfrom the mold thus eliminating the need for additional polishing orbuffing.

Rather than simply using a core to maintain open space, as is done in aconventional faucet, continuous internal waterway 110 serves as the coreof the mold for faucet 200, providing significant cost savings comparedto the conventional faucet. By utilizing continuous internal waterway110 as the core of the mold, many costs associated with metal casting ofconventional faucet bodies such as sand cores, casting voids, andpitting, are eliminated. Additionally, continuous internal waterway 110will provide significant cost savings compared to a conventional faucetbecause assembly is performed outside of faucet 200, rather than insideof a faucet body as is done in a conventional faucet.

In mold design, the core is maintained in a target position within themold. The core may be geometrically constrained within the mold. Thecore may be held in the mold by a series of mounting points. Mountingpoints may be located at locations where the mold supports the core, orpoints where the core mounts to the mold. For example, the mold mayinclude a number of posts configured to be received within the core,thereby supporting the core. In another example, the core may contain anumber of posts configured to be received within the mold, therebysupporting the core within the mold. Depending on the mold configuration(e.g., set up, lay out, etc.), different mounting points of continuousinternal waterway 110 within the mold may be necessary. The mold may beoriented in any fashion, such as a vertical or horizontal fashion.Depending on the orientation of the mold, different mounting points maybe necessary. In one embodiment, continuous internal waterway 110 isheld within the mold through the use of top opening print area cover170, bottom opening print area cover 180, and/or aerator print areacover 190. In this embodiment, top opening print area cover 170, bottomopening print area cover 180, and/or aerator print area cover 190 may bereceived within the mold. For example, the mold may have threeindividual openings each sized to receive one of the top opening printarea cover 170, the bottom opening print area cover 180, and/or theaerator print area cover 190 whereby continuous internal waterway 110may be suspended within the mold such that encapsulating material may beexposed to all sides of continuous internal waterway 110. In otherexamples, a different core support structure may be utilized such asvarious posts, spacers, or braces to support continuous internalwaterway 110 within the mold.

In the forming stage, body 112 may be formed from encapsulating materialthat is injected (e.g., poured, etc.) into the mold thereby surroundingcontinuous internal waterway 110 within the mold. According to anexemplary embodiment, body 112 is formed from a non-metallicencapsulating material. In some embodiments, body 112 is constructedfrom an encapsulating material that is a composite (e.g., particulatefilled thermoset, thermoplastic polymer resin, etc.) or a plastic. Forexample, body 112 may be constructed from an encapsulating material thatis made up of two or more disparate constituent materials. In otherexamples, body 112 may be constructed from other encapsulating materialssuch as inorganic ceramics, geopolymer cements, fiber wound composites,metallic alloys, fiber embedded composites, acrylic, acrylonitrilebutadiene styrene (ABS), nylon, polycarbonate, polypropylene,polystyrene, Teflon®, thermoplastic, thermoset, thermosetting polymer,resin, epoxy, or other suitable materials such that faucet 200 may betailored for a target application. According to various embodiments,body 112 is defined by a density. Accordingly, the encapsulatingmaterial of body 112 may be selected for a particular application basedon a desired density for a particular application. In some applications,it may be desirable to select a particular encapsulating material forbody 112 having an elevated density because added weight may signifyadded value to a consumer.

Once formed, faucet 200 may be removed from the mold. In thepost-forming stage, faucet preassembly 100 is removed from the mold, andtop opening print area cover 170, bottom opening print area cover 180,and aerator print area cover 190 are removed, resulting in faucet 200.Further, in the post-forming process faucet 200 may be cleaned andinspected, and other post-forming components (e.g., handles, knobs,etc.) may be coupled to faucet 200. Faucet 200 may then be installed ina target application (e.g., sink, vanity, countertop, etc.).

In the post-forming stage, top opening print area cover 170, bottomopening print area cover 180, and aerator print area cover 190 may beremoved from faucet pre-assembly 100. Any of top opening print areacover 170, bottom opening print area cover 180, and aerator print areacover 190 may be removed from faucet preassembly 100 using a materialremoval process such as machining (e.g., automated, manual). Faucet 200is formed once top opening print area cover 170, bottom opening printarea cover 180, and aerator print area cover 190 have been removed fromfaucet preassembly 100. According to various embodiments, faucet 200does not require machining, polishing, or buffing of any surface onceremoved from the mold. Accordingly, assembly time of faucet 200 may besignificantly lower than assembly time of a conventional faucet. Inother examples, faucet 200 may be subjected to a hexavalent chrome freemetallizing technology such as embedded physical vapor deposition. Afterbeing formed, faucet 200 may be inspected and cleaned. Handles, plumbingnetworks, and other components may then be installed on faucet 200.Alternatively, faucet 200 may then be installed in a plumbing fixturesuch as a vanity or countertop.

In application, adjustable valve system 120 and aerator 150 may beserviced or interchanged. For example, a user may remove a handle offaucet 200 to access adjustable valve system 120. Following thisexample, the user may remove adjustable valve system 120 for servicingand, once serviced, may simply reinstall adjustable valve system 120into faucet 200 and reinstall the handle on valve stem 192.

It is understood that additional stages or sub-stages may also beincluded in the construction of faucet 200 without departing from thescope of the present application. Similarly, it is understood that thesteps or sub-steps within the stages or sub-stages may be performed inany suitable combination or order without departing from the scope ofthe present application.

According to an exemplary operation, water may enter faucet 200 via aplumbing network inserted through bottom opening 160 coupled to plumbingconnection 194. In some embodiments, faucet 200 incorporates multipleplumbing connections 194. In one embodiment, faucet 200 incorporates oneplumbing connection 194 for hot water and one plumbing connection 194for cold water. After entering through plumbing connection 194, watermay enter valve seat 130. According to various embodiments, afterleaving valve seat 130, water enters adjustable valve system 120.Adjustable valve system 120 may be controlled via valve stem 192. Valvestem 192 may be coupled to a handle such that valve stem 192 may beinteracted with by a user. Valve stem 192 may be configured to adjustflow rate and/or temperature of water from faucet 200.

In various embodiments, adjustable valve system 120 controls the ratioof hot water to cold water and controls the flow rate of the combinedwater stream. In other embodiments, faucet 200 includes two adjustablevalve systems 120. According to these embodiments, faucet 200 has oneadjustable valve system 120 dedicated to control temperature of waterfrom faucet 200 and the other adjustable valve system 120 dedicated tocontrol flow rate of water from faucet 200. In some embodiments,adjustable valve system 120 includes more than one valve stem 192.According to an embodiment where hot and cold water are independentlyintroduced to valve seat 130 and adjustable valve system 120 through theuse of two pluming connections 194, the two independent water streamsare mixed in adjustable valve system 120 and are redirected into valveseat 130 as a single mixed water stream. Next, water from adjustablevalve system 120 may be redirected to valve seat 130. From valve seat130, water may traverse waterway 140 and enter aerator 150. Aerator 150may be a standard aerator or may be a functional aerator. For example,aerator 150 may have multiple settings (e.g., modes) allowing forvarious water dispersion patterns (e.g., spray, mist, pulsating, etc.).After exiting aerator 150, the mixed water may be accessible to a user.

Referring to FIGS. 3-6, various views of continuous internal waterway110 are shown. Continuous internal waterway 110 may incorporate featuresfor mounting in a mold. As shown in FIG. 3, adjustable valve system 120,waterway 140, and aerator 150 have a rounded exterior surface. However,in some applications, any of adjustable valve system 120, waterway 140,and aerator 150 may have a textured or otherwise shaped (e.g., square,polygonal, hexagonal, etc.) surface.

While body 112 has been described for faucet 200, it is understood thatbody 112 could be utilized to encapsulate a variety of differentstructure, components, and devices. For example, body 112 may beutilized to encapsulate electronics, sensors, and lights. Accordingly,continuous internal waterway 110 may similarly incorporate additionalcomponents such as electronics, sensors, and lights. While body 112 hasbeen described to form faucet 200, it is similarly understood that otherfaucets, fixtures, bath fixtures, water fixtures, lavatory fixtures, andplumbing fixtures may similarly be formed. For example, body 112 may beutilized to form a vanity integrated with a plumbing fixture (e.g.,faucet 200). Similarly, body 112 may be utilized to form a lavatoryfixture such as a toilet. In another example, body 112 may be utilizedto form a tray faucet, or components thereof. In other examples, body112 may be utilized to form handles that may be coupled to a plumbingfixture (e.g., faucet 200).

Referring to FIG. 7, a method 700 for constructing faucet 200 is shownaccording to an exemplary embodiment. Method 700 includes formingcontinuous internal waterway 110 by coupling valve seat 130 to bottomchamber 116 and to waterway 140 (step 702). Method 700 also includesplacing continuous internal waterway 110 in a mold (step 704). Method700 also includes forming body 112 around continuous internal waterway110 by surrounding continuous internal waterway 110 with encapsulatingmaterial in the mold (step 706). Method 700 also includes removing body112 from the mold (step 708). In some implementations of method 700,continuous internal waterway 110 is configured to receive water throughbottom chamber 116. Continuous internal waterway 110 may also beconfigured to provide water through valve seat 130 to waterway 140.Continuous internal waterway 110 may also be configured to provide waterfrom waterway 140. Further, body 112 does not form any portion ofcontinuous internal waterway 110 in some implementations of method 700.

Method 700 may also include covering at least one of valve seat 130 andbottom chamber 116 with top opening print area cover 170 and/or bottomopening print area cover 180 (step 710) before placing continuousinternal waterway 110 in the mold (step 704). In some implementations ofmethod 700, top opening print area cover 170 and/or bottom opening printarea cover 180 is configured to prevent the encapsulating material ofbody 112 from entering continuous internal waterway 110. Method 700 mayalso include removing top opening print area cover 170 and/or bottomopening print area cover 180 after body 112 has been removed from themold (step 712). Method 700 may also include coupling aerator 150 towaterway 140, aerator 150 forming a portion of continuous internalwaterway 110 (step 714). In some implementations of method 700,continuous internal waterway 110 is configured to provide the waterthrough aerator 150. Aerator 150 is at least partially contained withinbody 112 in some implementations of method 700.

Method 700 may also include covering aerator 150 with aerator print areacover 190 (step 716). Method 700 may also include removing aerator printarea cover 190 after body 112 has been removed from the mold (step 718).In some implementations, aerator print area cover 190 is configured toat least partially facilitate mounting of continuous internal waterway110 within the mold. Aerator print area cover 190 may be configured tocooperate with the mold to prevent the encapsulating material of body112 from entering continuous internal waterway 110. Continuous internalwaterway 110 may be defined by a maximum temperature associated with atemperature at which a portion of continuous internal waterway 110becomes undesirably affected by the temperature. The encapsulatingmaterial of body 112 may be defined by a processing temperatureassociated with a temperature at which the encapsulating material can beintroduced into the mold. The maximum temperature may be greater thanthe processing temperature. A ratio of the maximum temperature to theprocessing temperature may be equal to or greater than a factor ofsafety (e.g., 1.3, 1.4, 1.5, 1.6, etc.). The encapsulating material ofbody 112 may be non-metallic.

Referring to FIG. 8, a process 800 for constructing faucet 200 is shownaccording to an exemplary embodiment. Process 800 includes couplingvalve seat 130 to adjustable valve system 120, waterway 140, and bottomchamber 116 such that valve seat 130, adjustable valve system 120,waterway 140, and bottom chamber 116 are in fluid communication, therebyforming continuous internal waterway 110 (step 802). Process 800 alsoincludes covering adjustable valve system 120 with top opening printarea cover 170 (step 804). Top opening print area cover 170 may beremovably coupled to valve seat 130 and configured to cooperate withvalve seat 130 to cover adjustable valve system 120. Process 800 alsoincludes encapsulating continuous internal waterway 110 in a mold withan encapsulating material (e.g., a non-metallic encapsulating material,etc.), thereby forming body 112 around continuous internal waterway 110(step 806). Process 800 also includes removing body 112 from the mold(step 808). In some implementations of process 800, top opening printarea cover 170 prevents the encapsulating material from contactingadjustable valve system 120. Continuous internal waterway 110 may beconfigured to receive water through bottom chamber 116, to provide waterthrough valve seat 130 to waterway 140, and to provide water fromwaterway 140.

Process 800 may also include removing top opening print area cover 170after body 112 has been removed from the mold (step 810). Process 800may also include coupling aerator 150 to waterway 140, aerator 150forming a portion of continuous internal waterway 110 (step 812).Process 800 may also include covering aerator 150 with aerator printarea cover 190 (step 814). Process 800 may also include removing aeratorprint area cover 190 after body 112 has been removed from the mold (step816). Continuous internal waterway 110 may be configured to provide thewater through aerator 150. Aerator print area cover 190 may beconfigured to at least partially facilitate mounting of continuousinternal waterway 110 within the mold. In some implementations ofprocess 800, top opening print area cover 170 is configured to cooperatewith the mold to prevent the encapsulating material from enteringcontinuous internal waterway 110. Continuous internal waterway 110 maybe defined by a maximum temperature associated with a temperature atwhich a portion of continuous internal waterway 110 becomes undesirablyaffected by the temperature. Similarly, the encapsulating material ofbody 112 may be defined by a processing temperature associated with atemperature at which the encapsulating material of body 112 can beintroduced into the mold. The maximum temperature may be greater thanthe processing temperature.

In some embodiments, continuous internal waterway 110 includesadditional components, such as mounting hardware. For example, threadedposts may be incorporated into continuous internal waterway 110 suchthat faucet 200 includes the threaded posts. Similarly, other fasteners(e.g., bolts, screws, etc.) or fastener interfaces (e.g., threadedholes, etc.) may be incorporated into continuous internal waterway 110.In other examples, continuous internal waterway 110 may include handles.

A conventional faucet may experience leaks between various componentsthroughout the useful life of the conventional faucet. These leaks maybe undesirable and result in damage to the faucet and/or surroundingitems such as counters, floors, and walls. Faucet 200 may not be subjectto leaks at the same places as the conventional faucet due to thecontinuity of body 112.

While faucet 200 is shown to include only one plumbing connection 194,it is understood that faucet 200 may include multiple plumbingconnections such that faucet 200 may be tailored for a targetapplication. In various embodiments, faucet 200 and/or continuousinternal waterway 110 include various suitable hardware components(e.g., crush washers, washers, bushings, spacers, O-rings, etc.).According to various embodiments, faucet 200 is utilized in variousfaucet assemblies such as mono-block lavatory faucets, bridge stylekitchen faucets, bathfill faucets, or other suitable types of faucetssuch that the faucet assembly may be tailored for a target application.While faucet 200 has been referenced in regards to a supply of water, itis understood that other similar fluids could be utilized with faucet200.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described areconsidered to be within the scope of the present application.

It should be noted that the term “exemplary” as used herein to describevarious embodiments is intended to indicate that such embodiments arepossible examples, representations, and/or illustrations of possibleembodiments (and such term is not intended to connote that suchembodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

It is important to note that the construction and arrangement of thevarious exemplary embodiments are illustrative only. Although only a fewembodiments have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Forexample, elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of elements may be reversed orotherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. The order or sequence of any processor method steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and omissionsmay also be made in the design, operating conditions and arrangement ofthe various exemplary embodiments without departing from the scope ofthe present application.

What is claimed is:
 1. A faucet comprising: a continuous internalwaterway defined by a maximum temperature, the continuous internalwaterway comprising: a first body chamber; a second body chamberconfigured to receive water from a water source; a valve seat coupled tothe first body chamber and the second body chamber; and a waterway influid communication with the valve seat; and a one-piece body defined bya processing temperature less than the maximum temperature, theone-piece body encapsulating the continuous internal waterway; whereinthe faucet is operational to receive the water from the water source andto provide the water to the waterway; wherein the one-piece body isisolated from the water by the continuous internal waterway duringoperation of the faucet; wherein the valve seat is in fluidcommunication with the second body chamber; and wherein the first bodychamber is attached to the valve seat, the second body chamber isattached to the valve seat separate from the first body chamber, and thewaterway is attached to the valve seat separate from the first bodychamber and the second body chamber.
 2. The faucet of claim 1, whereinthe continuous internal waterway further comprises an adjustable valvesystem, the adjustable valve system configured to control an amount offluid provided by the faucet.
 3. The faucet of claim 2, wherein theadjustable valve system is contained within the first body chamber; andwherein the adjustable valve system includes a valve stem configured toreceive a user input to control the amount of fluid provided by thefaucet.
 4. The faucet of claim 2, wherein the processing temperature isassociated with a temperature at which the one-piece body can beintroduced into a mold to form around the continuous internal waterway.5. The faucet of claim 2, wherein the continuous internal waterwayfurther comprises an aerator in fluid communication with the waterway,the faucet configured to provide the water through the aerator; andwherein the aerator is at least partially contained within the one-piecebody.
 6. The faucet of claim 1, wherein the one-piece body isnon-metallic.
 7. A method for constructing a faucet comprising:separately attaching a valve seat to a bottom body chamber, a top bodychamber, and a waterway, the valve seat, the bottom body chamber, andwaterway forming a continuous internal waterway; placing the continuousinternal waterway in a mold; forming a one-piece body around thecontinuous internal waterway by surrounding the continuous internalwaterway with encapsulating material in the mold; and removing theone-piece body from the mold; wherein the continuous internal waterwayis configured to receive water through the bottom body chamber, toprovide water through the valve seat to the waterway, and to providewater from the waterway; wherein the continuous internal waterway iscontinuous within the one-piece body; and wherein the continuousinternal waterway is defined by a maximum temperature and theencapsulating material is defined by a processing temperature less thanthe maximum temperature.
 8. The method of claim 7, further comprisingcovering at least one of the valve seat and the bottom body chamber witha print area cover; wherein the print area cover is configured toprevent the encapsulating material from entering the continuous internalwaterway.
 9. The method of claim 8, further comprising removing the atleast one print area cover after the one-piece body has been removedfrom the mold.
 10. The method of claim 7, further comprising coupling anaerator to the waterway, the aerator forming a portion of the continuousinternal waterway; wherein the continuous internal waterway isconfigured to provide the water through the aerator; and wherein theaerator is at least partially contained within the one-piece body. 11.The method of claim 10, further comprising: covering the aerator with aprint area cover; and removing the print area cover after the one-piecebody has been removed from the mold; wherein the print area cover isconfigured to facilitate mounting of the continuous internal waterwaywithin the mold.
 12. The method of claim 11, wherein the print areacover is configured to cooperate with the mold to prevent theencapsulating material from entering the continuous internal waterway.13. The method of claim 7, wherein the processing temperature isassociated with a temperature at which the encapsulating material can beintroduced into the mold.
 14. The method of claim 7, wherein a ratio ofthe maximum temperature to the processing temperature is equal to orgreater than 1.3.
 15. The method of claim 7, wherein the encapsulatingmaterial is non-metallic.
 16. A process for manufacturing a faucet, theprocess comprising: separately attaching a valve seat to a bottom bodychamber, a top body chamber, and a waterway such that an adjustablevalve system, the waterway, and the bottom body chamber are in fluidcommunication and form a continuous internal waterway; covering theadjustable valve system with a print area cover, the print area coverremovably coupled to the valve seat and configured to cooperate with thevalve seat to cover the adjustable valve system; encapsulating thecontinuous internal waterway in a mold with a non-metallic encapsulatingmaterial, thereby forming a one-piece body around the continuousinternal waterway; and removing the one-piece body from the mold;wherein the print area cover prevents the non-metallic encapsulatingmaterial from contacting the adjustable valve system; wherein thecontinuous internal waterway is configured to receive water through thebottom body chamber, to provide water through the valve seat to thewaterway, and to provide water from the waterway; and wherein thecontinuous internal waterway is defined by a maximum temperature and thenon-metallic encapsulating material is defined by a processingtemperature less than the maximum temperature.
 17. The process of claim16, further comprising removing the print area cover after the one-piecebody has been removed from the mold.
 18. The process of claim 17,further comprising: coupling an aerator to the waterway, the aeratorforming a portion of the continuous internal waterway; covering theaerator with a second print area cover; and removing the second printarea cover after the one-piece body has been removed from the mold;wherein the continuous internal waterway is configured to provide thewater through the aerator; and wherein the second print area cover isconfigured to facilitate mounting of the continuous internal waterwaywithin the mold.
 19. The process of claim 16, wherein the print areacover is configured to cooperate with the mold to prevent thenon-metallic encapsulating material from entering the continuousinternal waterway.
 20. The process of claim 16, wherein the processingtemperature is associated with a temperature at which the non-metallicencapsulating material can be introduced into the mold.